Lean Lego Game Slides - Long Presentation

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The Lean Lego Game
Tuesday, 11 February 14

Quick Introduction
Simulating a production line
How about software ?
Agenda

Process

Hands On
Results
Debrieﬁng
Process

Hands On
Results
Debrieﬁng
Process
3x

Why ?

But without much contact
with Lean principles and
practices
Lean concepts
being used in the
software world
Why ?

“... over the years there have been some
ostensibly ‘lean’ promoters that reduced lean
thinking to a mechanistic superﬁcial level of
management tools such as kanban and queue
management.
... the essence of successful lean thinking is
building people, then building products and a
culture of “challenge the status quo
continuous improvement ” Lean Primer (http://tinyurl.com/owvhut)

We’re here to introduce you to Lean
“... over the years there have been some
ostensibly ‘lean’ promoters that reduced lean
thinking to a mechanistic superﬁcial level of
management tools such as kanban and queue
management.
... the essence of successful lean thinking is
building people, then building products and a
culture of “challenge the status quo
continuous improvement ” Lean Primer (http://tinyurl.com/owvhut)

LeanLean

Toyota Production
System
Toyota Production
System

Revolutionized
manufacturing

Revolutionized
manufacturing
Applied to
different areas

What we want to show

Push

Push
Pull

Push
Pull
Flow

Push
Pull
Flow
Systems Thinking

Push
Pull
Flow
Systems Thinking
Yatai

Push
Pull
Flow
Systems Thinking
Yatai
Heijunka

Hands on - 1st Step

Task 1 Task 2 Task 3 Task 4
Hands on - 1st Step

Hands on - 1st Step
4 Teams
30 secs
4 Rounds

Hands on - 1st Step
Follow the instructions
Build houses
1 Piece = $ 1.00
1 House = $ 25.00

What went wrong ?
Houston, we have a problem...

Visible Inventory
Over/Under Production
Waste

Visible Inventory
Over/Under Production
Waste
0
175
350
525
700
0 1 2 3 4
Task 1
Task 2
Task 3
Task 4

7 Wastes of Manufacturing

Overproduction

Overproduction
Waiting

Overproduction
Waiting
Overprocessing

Overproduction
Waiting
Unnecessary
Transportation
Overprocessing

Overproduction
Waiting
Unnecessary
Transportation
Overprocessing
Inventory

Overproduction
Waiting
Unnecessary
Transportation
Overprocessing
Inventory
Motion

Overproduction
Waiting
Unnecessary
Transportation
Overprocessing
Inventory
Motion
Defects

Push and Pull Systems

Push

Push
Expected
Demand

Push
Expected
Demand
Mass
Production

Push
Expected
Demand
Mass
Production
Economies
of Scale

Push
“Any colour, as
long as it’s black”
Henry Ford

Push
Mass
Production
Economies
of Scale
Expected
Demand

Pull
Push
Mass
Production
Economies
of Scale
Expected
Demand

Customer
Requirements
Pull
Push
Mass
Production
Economies
of Scale
Expected
Demand

On Demand
Production
Customer
Requirements
Pull
Push
Mass
Production
Economies
of Scale
Expected
Demand

Adaptation
On Demand
Production
Customer
Requirements
Pull
Push
Mass
Production
Economies
of Scale
Expected
Demand

Pull

Kanban
TASK1
TASK2

Kanban
TASK1
TASK2
Signals demand
Regulates demand
Limits Work in Process
Aids visual control
Self-directing

Kanban
Signals demand
Regulates demand
Limits Work in Process
Aids visual control
Self-directing

Hands on - 2nd Step
Pull System

Task 4Task 1 Task 2 Task 3
Hands on - 2nd Step
Pull System

Hands on - 2nd Step
4 Teams
30 secs
4 RoundsPull System

Hands on - 2nd Step
Pull System
Setup minimum buffers at intermediate steps
Demand comes ﬁrst
Items are produced to ﬁll gaps in the buffers

Hands on - 2nd Step
Pull System
Setup minimum buffers at intermediate steps
Demand comes ﬁrst
Items are produced to ﬁll gaps in the buffers
Kanban

Unleveled Process
Another type of waste
Some people working more than others
Mura (Unevenness)
Heijunka

Flow
Goal is a leveled process
Production line must be a continuous ﬂow
One piece is bought when one piece is delivered
Sustainable pace

Flow
Sustainable pace
Watch the baton, not the runners
Lean Primer (http://tinyurl.com/owvhut)

Sustainable pace
Watch the baton, not the runners
Lean Primer (http://tinyurl.com/owvhut)
Flow

Flow
http://www.youtube.com/watch?v=nq9SnHXIG00

Systems Thinking
Why does it still feel wrong?
What are the other teams doing?
What’s the purpose of the system?

Systems Thinking
“A bad system
will beat a
good person
every time”
W. Eduards Deming

Do we need 4 teams to build a house?
Teams 1 and 2 have overlapping tasks
Systems Thinking

Yatai (Work Cell)
Multi-skilled worker
Single piece ﬂow

Hands on - 3rd Step

Sell house Build
Hands on - 3rd Step

Sell house Build
Hands on - 3rd Step
Each person builds a house
Round of 120 seconds
Signal if you ﬁnish it

Kaizen
Continuous Improvement
Reﬂect and adapt
Learn by standardizing
Long term thinking
Respect People

Kaizen
Continuous Improvement
Reﬂect and adapt
Learn by standardizing
Long term thinking
Respect People
“Toyota’s real advantage was its ability to
harness the intellect of ‘ordinary’ employees”
Gary Hamel

Is that all ?

Is that all ?
Push System

Is that all ?
Push System
Pull System

Is that all ?
Push System
Pull System
Yatai

Is that all ?
Push System
Pull System
Yatai
What’s next ?

Is that all ?
We saw some of the practices
Practices are contextual
Principles must be understood
Push System
Pull System
Yatai

What is Lean ?
What TPS is Not
A recipe for success
A management project or program
A set of tools for implementation
A system for production ﬂoor only
Implementable in a short- or mid- term period

What is Lean ?
What TPS is
A consistent way of thinking
A total management philosophy
Focus on total customer satisfaction
An environment of teamwork and improvement
A never ending search for a better way

Lean in Software Development

X

Overproduction
Waiting
Unnecessary Transportation
Overprocessing
Inventory
Motion
Defects

Overproduction
Waiting
Overprocessing
Inventory
Motion
Defects

Overproduction
Waiting
Overprocessing
Inventory
Motion
Defects
Extra Features
Gold Plating
Partially Completed Work
Unused Employee Creativity

Kanban Board

Controlling Kanban
Do you have a stable process ?

Controlling Kanban

Much more:

Eliminate Waste
Create Knowledge
Build Quality In
Defer Commitment
Deliver Fast
Respect People
Improve System
Much more:

Eliminate Waste
Create Knowledge
Build Quality In
Defer Commitment
Deliver Fast
Respect People
Improve System
Much more:
Genchi Genbutsu
A3
5 Whys?
Stop the Line
Andon
Jidoka
Mistake Prooﬁng

Thank You!
Questions ?

Lean Lego Game Slides - Long Presentation

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